Compressed Air Best Practices - June 2008 - (Page 40)

| 06–07/08 Compressed Air Industry PHARMACEUTICALS | UTILITY GRADE COMPRESSED AIR SYSTEMS Collecting and analyzing the baseline data provides an understanding of the current system. Potential challenges encountered when creating a utility grade system are compressor manufacturers, risk management, project scope, compressed air leaks and determining operating cost. Compressor Manufacturers Over the years, compressor manufacturers have developed system strategies, which may or may not match the needs and requirements of your utility grade system. Based on experience, it can be very beneficial to use one manufacturer that can supply all major compressed air (supply side) components including integrated controls. While this can be challenging, the benefits can be seen in operation, maintenance, warranty, integration, purchasing power and technical support. In lieu of a single source for all components, another option is to negotiate a comprehensive warranty covering all components. Both of these options will help eliminate “finger pointing” when problems arise. Many compressed air systems are designed by the compressor manufacturer as part of the sales process. While they have a very strong knowledge of their compressed air components, they tend to make their equipment match your needs and requirements. This may result in a sub-optimized system. Risk Management This system uses rotating machinery and therefore, it will fail! One of the key questions is, “How much or how long can production be interrupted?” If production demands zero downtime (i.e. zero observed failure), this can be designed into the system but it will require a tremendous cost. In other words, “How much risk is tolerable?” Some options to reduce risk may include backup compressors, inventory of critical spare parts, redundant control scheme, alternate electrical power, universal power supply backup, strategic bypass of major components, on-site factory response time and a knowledgeable maintenance staff. Eliminating or reducing risk equates to higher system costs. Project Scope The biggest factor in developing the project scope is determining the decision makers and system owners. It is necessary to understand their goals and objectives as they may be based on perceptions and not facts. An assembly line decision maker may state the process requires 120 psi based on events that happened years ago. Another classic response may be, “that’s the way it’s always been.” When in fact, the process only requires a constant pressure of 90 psi. As a rule of thumb, reducing overall operating pressure by 2 psi saves 1% in energy costs. The facts and information gathered in the baseline analysis will aid the decision makers in separating process needs from personal wants. Other examples may include facility limitations, future growth, air quality, dew points and return on investment. Compressed Air Leaks Typical leaks can account for upward of 30% of the overall compressor output. How much cost can be eliminated by just fixing half of the leaks? Knowing your leak rate and developing an aggressive leak detection program can prevent purchasing an unnecessary compressor thereby reducing overall project cost. A utility grade leak detection system strives to achieve a maximum of 5% of total system horsepower for leaks. Determining Operating Cost What is the true energy cost of running the current system? This is not an easy question to answer. It may require data logging along with reviewing and understanding utility rates and maintenance records. Typical compressed air performance is ~ 2.7 cfm/kW where utility grade system is ~ 5.5 cfm/kW (cfm = cubic feet per minute). This equates to a 50% reduction in operating costs. Estimating energy cost: One horsepower (hp) compressor motor running 24/7, 365 days/year, at $0.10/kWh costs $650/yr to operate. From this, a simple rule of thumb is: 1 hp ≈ $650/yr. (Note: This does not include costs associated with support systems, depreciation, taxes, and maintenance.) Therefore, for each 1,000 hp of compressors in operation equates to an electrical cost of $650,000/yr. Recall a utility grade compressed air system can achieve 50% reduction in operating cost. Is cutting energy cost by $325,000 and significantly increasing reliability and quality while reducing maintenance by achieving a utility grade compressed air system worth the investment? Case Study Recently, a major US manufacturer installed a utility grade central compressed air system — perhaps one of the most energy-efficient systems in the country, if not the world. Their original compressed air system was similar to many other large industrial systems comprised of remote compressors by various manufacturers serving multiple points in a fragmented distribution system. The system included 24 compressors totaling 4,200 hp in seven different facilities located on a common campus. There was little or no control between compressors, insufficient system response, inadequate storage and significant leakage. These factors caused inadequate capacity, slow system response and pressure fluctuations during peak 40 0 www .aii rbe stp rac tic es.com ai b t p racti tices com http://www.airbestpractices.com

Table of Contents Feed for the Digital Edition of Compressed Air Best Practices - June 2008

Compressed Air Best Practices - June 2008 Contents From the Editor Utility-Air News A Pharmaceutical Compressed Air System Audit Talking Dew Point Puerto Rico, Pharmaceuticals and Airequipo Inc. Oil-Free Rotary and Oil-Free Centrifugal Compressor Comparison SMC: Managing Energy and Dew Point in Pneumatic Systems Utility Grade Compressed Air Systems Training Calendar & Product Picks Wall Street Watch Advertiser Index Job Market

Compressed Air Best Practices - June 2008

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